Method for making a multilayer adhesive laminate

ABSTRACT

A method allows for rapid manufacture of relatively thick adhesive coatings using a continuous process, where a single thin coating is continuously converted into a single thicker adhesive laminate. An exemplary process includes the steps of: (1) producing a web having a first surface with an adhesive layer and a second surface with a release liner; (2) slitting the web longitudinally into a first section and a second section, (3) laminating a backing film to the adhesive layer of the first section; (4) removing the release liner of the laminate of step (3) exposing the adhesive layer of the first section; and (5) laminating the second section to the laminate of step (4), wherein the adhesive layer of the laminate of step (4) is combined with the adhesive layer of the second section.

PRIORITY

This application claims priority from the disclosure of U.S. ProvisionalPatent Application Ser. No. 61/102,223, entitled “Method for Making aMultilayer Adhesive Laminate,” filed Oct. 2, 2008, the disclosure ofwhich is incorporated by reference herein.

FIELD OF THE INVENTION

This invention is in the field of pressure sensitive adhesive coatings.

BACKGROUND

Pressure-sensitive adhesive laminates are common in products fromnumerous industries, including the medical and consumer healthcareindustries. Within these industries, pressure-sensitive adhesivelaminates may be used for transdermal patches, medical tapes, wounddressings, and topical skin patches. While this section and thedisclosure herein may focus on medical and consumer healthcareapplications, it should be understood that this disclosure is notlimited to these applications or industries.

A common process used to manufacture pressure-sensitive adhesivelaminates involves a continuous solvent-based adhesive coating process.Such a process may employ any suitable type of solvent, including water.However, the thickness of the adhesive coating produced by such aprocess is limited. For instance, to achieve a thicker adhesive-coatedproduct using a solvent-based adhesive coating processes, it isnecessary to slow production speeds to give thicker adhesive coatingsadequate drying time, or increase temperatures, which may cause theformation of surface imperfections. Alternatively, one may use such aprocess in batch mode to combine layers to produce thicker adhesivelaminates. These approaches to producing thick or multilayer adhesivelaminates are cost intensive and inefficient. Therefore, there is a needfor a process that allows for continuous rapid manufacture of arelatively thick adhesive laminate.

SUMMARY

The processes described herein allow for continuous rapid manufacture ofrelatively thin adhesive coatings, where the thin coatings arecontinuously manufactured into a single thicker adhesive laminate.

In one embodiment, this disclosure pertains to a method of continuouslymanufacturing a multilayer pressure-sensitive adhesive laminateincluding the steps of: (1) producing a web having a first surface withan adhesive layer and a second surface with a release liner; (2)slitting the web longitudinally into a first section and a secondsection, each section having a first surface with an adhesive layer anda second surface with a release liner; (3) positioning the first sectionand second section so the adhesive layer of the first section faces theadhesive layer of the second section along the length of the first andsecond sections; and (4) laminating the first section and second sectiontogether such that the adhesive layers of the first and second sectionsare attached. The resultant laminate has two surfaces each having arelease liner and an inner area having an adhesive layer.

In another embodiment, this disclosure pertains to a method ofcontinuously manufacturing a multilayer pressure-sensitive adhesivelaminate including the steps of: (1) producing a web having a firstsurface with an adhesive layer and a second surface with a releaseliner; (2) slitting the web longitudinally into a first section and asecond section, each section having a first surface with an adhesivelayer and a second surface with a release liner; (3) laminating abacking film to the adhesive layer of the first section; (4) removingthe release liner of the laminate of step (3) and exposing the adhesivelayer of the first section; (5) positioning the laminate of step (4) andthe second section so the exposed adhesive layer of the laminate of step(4) faces the adhesive layer of the second section; and (6) laminatingthe second section to the laminate of step (4), wherein the adhesivelayer of the laminate of step (4) is combined with the adhesive layer ofthe second section. The final laminate has one surface having a backingfilm, one surface having a release liner, and an inner area having anadhesive layer.

In another embodiment, this disclosure pertains to a method ofcontinuously manufacturing a multilayer pressure-sensitive adhesivelaminate including the steps of: (1) producing a web having a firstsurface with an adhesive layer and a second surface with a releaseliner; (2) slitting the web longitudinally into a plurality of sections,each of the plurality of sections having a first surface with anadhesive layer and a second surface with a release liner; (3) laminatinga backing film to the adhesive layer of a first section of the pluralityof sections; (4) removing the release liner of the laminate of step (3)and exposing the adhesive layer associated with the first section; (5)positioning the laminate of step (4) and a next section of the pluralityof sections so the exposed adhesive layer of the laminate of step (4)faces the adhesive layer of the next section; (6) laminating the nextsection to the laminate of step (4), wherein the adhesive layer of thelaminate of step (4) is combined with the adhesive layer of the nextsection; (7) removing the release liner of the laminate of step (6)exposing the adhesive layer associated with the next section; and (8)repeating steps (5) through (7) to achieve a desired number of laminatedlayers; wherein step (7) is omitted with the final laminated section ofthe plurality of sections. The final laminate has one surface having abacking film, one surface having a release liner, and an inner areahaving an adhesive layer.

The above embodiments are exemplary only and should not be interpretedto limit the scope of this disclosure. It should be understood that thisdisclosure encompasses numerous embodiments, some of which are notexplicitly disclosed within this section. Ultimately, the scope of thisdisclosure is defined by the broadest reading of the claims herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated in and constitute a part ofthis specification. Together with the detailed description given below,the drawings serve to explain how the teachings of this applicationcould be implemented. It should be understood that the teachings of thisapplication are not limited to being implemented in the precisearrangements shown. In the drawings:

FIG. 1A depicts a flow diagram of a method to make a multilayer adhesivelaminate having an adhesive coating between two release liners.

FIG. 1B depicts a schematic diagram of an exemplary process for themethod shown in FIG. 1A.

FIG. 1C depicts a cross-section view of the adhesive coated releaseliner strips used in the lamination process of FIG. 1B.

FIG. 1D depicts a cross-section view of the multilayer adhesive laminateproduced in the lamination process of FIG. 1B.

FIG. 2A depicts a flow diagram of a method to make a multilayer adhesivelaminate having an adhesive coating between a release liner and abacking film.

FIG. 2B depicts a schematic diagram of an exemplary process for themethod shown in FIG. 2A.

FIG. 2C depicts a cross-section view of the adhesive coated releaseliner strips used in the lamination process of FIG. 2B.

FIG. 2D depicts a cross-section view of the adhesive coated releaseliner strip containing the backing film as used in the laminationprocess of FIG. 2B.

FIG. 2E depicts a cross-section view of the strip of FIG. 2D with therelease liner removed.

FIG. 2F depicts a cross-section view of the multilayer adhesive laminateproduced in the lamination process of FIG. 2B.

FIG. 3A depicts a flow diagram of a method to make a multilayer adhesivelaminate having an adhesive coating between a release liner and abacking film.

FIG. 3B depicts a schematic diagram of an exemplary process for themethod shown in FIG. 3A.

FIG. 3C depicts a cross-section view of the adhesive coated releaseliner strips used in the lamination process of FIG. 3B

FIG. 3D depicts a cross-section view of the adhesive coated releaseliner strip containing the backing film as used in the laminationprocess of FIG. 3B.

FIG. 3E depicts a cross-section view of the strip of FIG. 3D with therelease liner removed.

FIG. 3F depicts a cross-section view of the strip of FIG. 3E after anadditional strip of adhesive coated release liner has been laminated tothe strip of FIG. 3E.

FIG. 3G depicts a cross-section view of the strip of FIG. 3F with therelease liner removed.

FIG. 3H depicts a cross-section view of the strip of FIG. 3G after anadditional strip of adhesive coated release liner has been laminated tothe strip of FIG. 3G.

FIG. 3I depicts a cross-section view of the multilayer adhesive laminateproduced in the lamination process of FIG. 3B.

DETAILED DESCRIPTION

In discussing the figures, specific frame of reference conventions aredesignated, which includes describing an upward and downwardorientation. When viewing the exemplary process figures (FIGS. 1B, 2B,and 3B), an upward orientation is associated with an object facingout-of-the-page, whereas a downward orientation is associated with anobject facing into-the-page. When viewing the laminate schematic figures(FIGS. 1C-1D, 2C-2F, and 3C-3I), an upward orientation is associatedwith an object facing the top of the page, whereas a downwardorientation is associated with an object facing the bottom of the page.These frame of reference conventions are used only for aiding inunderstanding the disclosure. In no sense should the disclosure belimited to such a frame of reference as other suitable manners ofdescription fall within the scope of this disclosure.

FIG. 1A describes a process for manufacturing a multilayer adhesivelaminate by pairing two adhesive coatings between release liners. Atstep 100, a coating of adhesive is applied to a release liner, using anysuitable coating method, to produce a coated web. Step 105 is a curingprocess, using any suitable method, where the adhesive-coated web isconverted from a fluid to a fixed film. A suitable curing process mayinclude, but is not limited to, a drying process. At step 110, the curedweb is slit into two strips using any suitable slitting method. At step115, the separate strips are directed through the process to orient theadhesive layers of the two strips such that they face one another inpreparation for lamination. At step 125, the adhesive layers of the twostrips are laminated together, using any suitable lamination method, toform a multilayer adhesive laminate having an inner adhesive layersurrounded on both sides by a release liner.

Referring to FIG. 1B, a schematic shows an exemplary way to direct thestrips to achieve the multilayer adhesive laminate discussed in FIG. 1A.In FIG. 1B, web section 130 is the adhesive coated web after curing step105 of FIG. 1A. Web section 130 travels through slitter 135 where websection 130 is divided into strip sections 140 and 145. Strip section140 travels over 45-degree turning roller 160, which causes a change inthe surface orientation of strip section 140, and causes strip section140 to change its direction of travel by about 90-degrees. FIGS. 1B and1C show that before strip section 140 passes over 45-degree turningroller 160, adhesive layer 175 of strip section 140 faces upward (andconversely the release liner 180 faces downward). After passing over45-degree turning roller 160, adhesive layer 175 of strip section 140faces downward (and conversely the release liner 180 faces upward).

Still referring to FIG. 1B, strip section 145 is directed to 90-degreeturning roller 150, which causes a change in the surface orientation ofstrip section 145, and causes strip section 145 to reverse its directionof travel. As shown from FIGS. 1B and 1C, adhesive layer 190 of stripsection 145 faces upward (and conversely the release liner 185 facesdownward) before passing over 90-degree turning roller 150. Afterpassing over 90-degree turning roller 150, adhesive layer 190 of stripsection 145 faces downward (and conversely the release liner 185 facesupward). Strip section 145 is then directed to 45-degree turning roller155, which causes a change in the surface orientation of strip section145, and causes strip section 145 to change its direction of travel byabout 90-degrees. As shown in FIG. 1B, 45-degree turning roller 155 islocated such that after turning roller 155, strip section 145 alignswith strip section 140, and strip section 140 travels above stripsection 145 in the same direction. Those of ordinary skill in the artwill appreciate that heights of strip sections 140 and 145 may bemanipulated by positioning turning rollers or web guides at differentheights with respect to a common plane of reference. Furthermore, asshown in FIG. 1B, after passing over 45-degree turning roller 155,adhesive layer 190 of strip section 145 now faces adhesive layer 175 ofstrip section 140.

Still referring to FIG. 1B, with strip sections 140 and 145 oriented asdescribed above, strip sections 140 and 145 then pass through alamination section 165. Lamination section 165 causes the adhesivelayers 175 and 190, of strip sections 140 and 145 respectively, to joinforming a multilayer adhesive laminate 170. As shown in FIGS. 1B and 1D,the multilayer adhesive laminate 170 has a combined adhesive layer 195,surrounded on either side by release liners 180 and 185. It should benoted that combined adhesive layer 195 is comprised of adhesive layer175 of strip section 140 and adhesive layer 190 of strip section 145.

Now referring to FIG. 2A, a process is shown for manufacturing amultilayer adhesive laminate by pairing two adhesive coatings between arelease liner and a backing film. At step 200, an adhesive coating isapplied to a release liner using any suitable coating method. At step205, the web containing the adhesive coating and release liner is curedusing any suitable method. At step 210, the web is slit into two stripsusing any suitable slitting method. At step 215 a backing film isattached to the adhesive layer of one of the strips. From this samestrip, at step 220, the release liner is removed, thus exposing theadhesive layer of the strip opposite the side of the backing film. Atstep 223, the separate strips are then directed through the process toorient the adhesive layers of the two strips such that they face oneanother in preparation for lamination. At step 225 the adhesive layersof the two strips are laminated together using any suitable laminationmethod to form a multilayer adhesive laminate.

Referring to FIGS. 2B-2F, a schematic shows an exemplary way to directthe strips to achieve the multilayer adhesive laminate discussed in FIG.2A. In FIG. 2B, web section 230 is the adhesive-coated web after curingstep 205 of FIG. 2A. Web section 230 travels through slitter 235 whereweb section 230 is divided into strip sections 240 and 245. Stripsection 245 travels to backing film application section 255, wherebacking film 250 is attached to adhesive layer 295 of strip section 245to produce strip section 290 having a backing film 250, an adhesivelayer 295, and a release liner 265 as shown in FIGS. 2B and 2D. Stripsection 290 then travels to a release liner removal section 260. Releaseliner 265 is removed from strip section 290 to produce strip section296. As shown in FIG. 2E, strip section 296 has backing film 250 on topof adhesive layer 295, which now has an exposed adhesive surface whererelease liner 265 was formerly positioned. Strip section 296 travelsover 45-degree turning roller 275, which causes a change in the surfaceorientation of strip section 296, and causes strip section 296 to changeits direction of travel by about 90-degrees. FIGS. 2B and 2E show thatbefore strip section 296 passes over 45-degree turning roller 275,backing film 250 of strip section 296 faces upward (and conversely theadhesive layer 295 faces downward). After passing over 45-degree turningroller 275, backing film 250 of strip section 296 faces downward (andconversely the adhesive layer 295 faces upward).

Still referring to FIGS. 2B-2F, strip section 240 is directed into45-degree turning roller 270, which causes a change in the surfaceorientation of strip section 240, and causes strip section 240 to changeits direction of travel by about 90-degrees. FIGS. 2B and 2C show thatbefore strip section 240 passes over 45-degree turning roller 270,adhesive layer 299 of strip section 240 faces upward (and conversely therelease liner 297 faces downward). After passing over 45-degree turningroller 270, adhesive layer 299 of strip section 240 faces downward (andconversely the release liner 297 faces upward). As shown in FIG. 2B,45-degree turning rollers 270 and 275 are located such that stripsections 240 and 296 align, and such that strip section 240 is travelingabove strip section 296 and in the same direction and speed. Those ofordinary skill in the art will appreciate that heights of strip sections240 and 296 may be manipulated by positioning turning rollers or webguides at different heights with respect to a common plane of reference.Furthermore, as shown in FIGS. 2B, 2C, and 2E, after passing over45-degree turning roller 270, adhesive layer 299 of strip section 240 isnow oriented facing adhesive layer 295 of strip section 296.

Still referring to FIGS. 2B-2F, with strip sections 240 and 296 orientedas described above, strip sections 240 and 296 then pass through alamination section 280. Lamination section 280 causes the adhesivelayers of strip sections 240 and 296, to join forming a multilayeradhesive laminate 285. As shown in FIGS. 2B and 2F, the multilayeradhesive laminate 285 has a combined adhesive layer 298 surrounded onone side by backing film 250 and one the other side by release liner297. It should be noted that combined adhesive layer 298 is comprised ofadhesive layer 299 of strip section 240 and adhesive layer 295 of stripsection 245.

Now referring to FIG. 3A, a process is shown for manufacturing amultilayer adhesive laminate by combining a multitude of adhesivecoatings between a single release liner and single backing film. At step300, an adhesive coating is applied to a release liner using anysuitable coating method. At step 305, the web containing theadhesive-coating and release liner is cured using any suitable method.At step 310 the web is slit into several strips using any suitableslitting method. At step 315 a backing film is attached to the adhesivelayer of a first strip. From this first strip, at step 320, the releaseliner is removed, thus exposing the adhesive layer of the first strip,opposite the side of the backing film. At step 323, a second strip isthen directed through the process to orient its adhesive layer such thatit faces the exposed adhesive layer of the first strip. At step 325, theadhesive layer of the second strip is laminated to the exposed adhesivelayer of the first strip using any suitable lamination process. At step330, the release liner of the second strip is removed, thus exposing theadhesive layer of the second strip, opposite the side laminated to thefirst strip. At step 333, a third strip is then directed through theprocess to orient its adhesive layer such that it faces the exposedadhesive layer of the second strip. At step 335, the adhesive layer ofthe third strip is laminated to the exposed adhesive layer of the secondstrip using any suitable lamination process. At step 340, steps 330,333, and 335 are repeated with the next available strip for lamination.However, step 340 concludes by not removing the release liner of thefinal laminated strip, thus forming the multilayer adhesive laminate.

Referring to FIGS. 3B-3H, a schematic shows an exemplary way to directthe strips to achieve the multilayer adhesive laminate discussed in FIG.3A. In FIG. 3B, web section 345 is the adhesive coated web after curingstep 305 of FIG. 3A. Web section 345 travels through slitter section 346where web section 345 is divided into a plurality of strip sections 347,348, 349, 350, 351, 352, 353, and 354. Strip section 354 has an adhesivelayer 391 on a release liner 356 as shown in FIG. 3C. Each of stripsections 347, 348, 349, 351, 352, and 353 have a similar adhesive layeron release liner structure as shown in FIG. 3C with respect to stripsection 354.

Still referring to FIGS. 3B-3H, strip section 354 travels to backingfilm application section 363, where backing film 355 is attached toadhesive layer 391 of strip section 354 to produce a strip section 393having a backing film 355, an adhesive layer 391, and a release liner356 as shown in FIG. 3D. Strip section 393 then travels to a releaseliner removal section 371. Release liner 356 is removed from stripsection 393 to produce strip section 394. As shown in FIG. 3E, stripsection 394 has backing film 355 on adhesive layer 391, which now has anexposed adhesive surface where release liner 356 was formerlypositioned.

Strip section 353 travels into 45-degree turning roller (shown inphantom in drawing), which causes a change in the surface orientation ofstrip section 353, and causes strip section 353 to change its directionof travel by about 90-degrees. FIG. 3B shows that before strip section353 passes over the 45-degree turning roller, the adhesive layer ofstrip section 353 faces upward (and conversely the release liner 357faces downward). After passing over the 45-degree turning roller, theadhesive layer of strip section 353 faces downward (and conversely therelease liner 357 faces upward). Strip section 353 continues intoanother 45-degree turning roller (shown in phantom in drawing), whichagain causes a change in the surface orientation of strip section 353,and causes strip section 353 to change its direction of travel by about90-degrees. FIG. 3B shows that before strip section 353 passes over thesecond 45-degree turning roller, the adhesive layer of strip section 353faces downward (and conversely the release liner 357 faces upward).After passing over the second 45-degree turning roller, the adhesivelayer of strip section 353 faces upward (and conversely the releaseliner 357 faces downward). As shown in FIGS. 3B and 3E, the 45-degreeturning rollers that guide strip section 353 are located such that, atthe exit of the second 45-degree turning roller, strip section 353aligns with strip section 394, and strip section 353 is traveling belowstrip section 394 in the same direction and speed. Those of ordinaryskill in the art will appreciate that heights of strip sections 353 and394 may be manipulated by positioning turning rollers or web path guidesat different heights with respect to a common plane of reference.Furthermore, after passing over the second 45-degree turning roller, theadhesive layer of strip section 353 faces the exposed adhesive layer 391of strip section 394.

Still referring to FIGS. 3B-3H, with strip sections 353 and 394 orientedas described above, strip sections 353 and 394 then pass through alamination section 364. Lamination section 364 causes the adhesivelayers of strip sections 353 and 394, to join together forming a stripsection 395 as shown in FIG. 3F. Strip section 395 has a combinedadhesive layer 392 surrounded on one side by backing film 355 and on theopposite side by release liner 357. It should be noted that combinedadhesive layer 392 is comprised of adhesive layer 391 of strip section394 and the adhesive layer of strip section 353.

Still referring to FIGS. 3B-3H, strip section 395 then travels to arelease liner removal section 372. Release liner 357 is removed fromstrip section 395 to produce strip section 396. As shown in FIG. 3G,strip section 396 has backing film 355 on top of combined adhesive layer392, which now has an exposed adhesive surface where release liner 357was formerly positioned.

Strip section 352 travels into 45-degree turning roller 383, whichcauses a change in the surface orientation of strip section 352, andcauses strip section 352 to change its direction of travel by about90-degrees. FIG. 3B shows that before strip section 352 passes over45-degree turning roller 383, the adhesive layer of strip section 352faces upward (and conversely the release liner 358 faces downward).After passing over 45-degree turning roller 383, the adhesive layer ofstrip section 352 faces downward (and conversely the release liner 358faces upward). Strip section 352 continues into another 45-degreeturning roller 389, which again causes a change in the surfaceorientation of strip section 352, and causes strip section 352 to changeits direction of travel by about 90-degrees. FIG. 3B shows that beforestrip section 352 passes over 45-degree turning roller 389, the adhesivelayer of strip section 352 faces downward (and conversely the releaseliner 358 faces upward). After passing over 45-degree turning roller389, the adhesive layer of strip section 352 faces upward (andconversely the release liner 358 faces downward). As shown in FIGS. 3Band 3G, 45-degree turning rollers 383, 389 that guide strip section 352are located such that, at the exit of 45-degree turning roller 389,strip section 352 aligns with strip section 396, and strip section 352is traveling below strip section 396 in the same direction and speed.Those of ordinary skill in the art will appreciate that heights of stripsections 352 and 396 may be manipulated by positioning turning rollersor web path guides at different heights with respect to a common planeof reference. Furthermore, after passing over 45-degree turning roller389, the adhesive layer of strip section 352 faces the exposed adhesivelayer 392 of strip section 396.

Still referring to FIGS. 3B-3H, with strip sections 352 and 396 orientedas described above, strip sections 352 and 396 then pass through alamination section 365. Lamination section 365 causes the adhesivelayers of strip sections 352 and 396, to join forming a strip section397 as shown in FIG. 3H. Strip section 397 has a combined adhesive layer398 surrounded on one side by backing film 355 and on the opposite sideby release liner 358. It should be noted that combined adhesive layer398 is comprised of adhesive layer 392 of strip section 396 and theadhesive layer of strip section 352.

As shown in FIGS. 3A and 3B, the process described in the precedingparagraphs repeats to achieve the desired laminate thickness. Morespecifically, release liner 358 of strip section 397 is removed andstrip section 351 is positioned using 45-degree turning rollers forlamination. As shown in FIG. 3B, after final strip section 347 islaminated to the intermediate product, the release liner of stripsection 347 is maintained on the laminate to produce the finalmultilayer adhesive laminate 390 as shown in FIGS. 3B and 3I. The finalmultilayer adhesive laminate 390 has a combined adhesive layer 399surrounded on one side by backing film 355 and on the other side byrelease liner 400. It should be noted that combined adhesive layer 399is comprised of the adhesive layers of strip sections 354, 353, 352,351, 350, 349, 348, and 347.

While the above paragraphs have described several product features, thisdisclosure should not be limited to the precise features shown anddescribed. For example, the adhesive coating disclosed may be of any ofseveral types. For instance, the adhesive coating may be a solvent basedadhesive coating for use in a transdermal or topical medical patch. Insuch examples, the adhesive coating may contain medicinal formulationsfor the treatment of certain ailments. By way of example and notlimitation, to treat skin pain or discomfort, lidocaine may be combinedwith the adhesive to create a skin treatment patch. Those of ordinaryskill in the art will appreciate that the adhesive may be combined withany suitable medicinal formulation, where topical or transdermal drugdelivery is desired.

Additional medical related applications for a multilayer adhesivelaminate as disclosed herein may include medical tapes, wound dressings,ostomy adhesives, and numerous others. Similarly, the multilayeradhesive laminate disclosed herein, may have applications in otherindustries where a thick coating of pressure-sensitive adhesive isdesirable; for example, applications may exist in consumer products,automotive, and home improvement industries.

Some additional product features described include release liners andbacking films. It should be understood that this disclosure shallencompass any variety of release liners and backing films suitable foradhering to an adhesive coating. By way of example only, release linersand backing films may be manufactured from natural or synthetic fibersthat may be woven, nonwoven, melt cast, or extruded. Furthermore, acombination of natural or synthetic fibers may be used. Those ofordinary skill in the art will appreciate the variety of materialssuitable for use as both release liners and backing films.

The above disclosure also describes several process features, and thedisclosure should not be limited to the precise process features shownor described. For example, several web-guiding structures are disclosedincluding 45-degree and 90-degree turning rollers. It should beunderstood, that in some embodiments such turning rollers may be drivenor braked, while in other embodiments such turning rollers may be freelyrotating. Still in other embodiments, turning rollers may beinterchanged with turning or guide bars that do not rotate. Similarly,the precise degrees specified for the turning rollers are not requiredand maybe substituted with turning rollers having other degreeconfigurations.

Some additional process features described include coating, curing,slitting, and laminating processes. It should be understood that thisdisclosure is not intended to be limited to a specific method forconducting any of these processes. For example, several types ofcoating, curing, slitting, and laminating processes may be compatiblewith this disclosure. By way of example only, the adhesive coating maybe accomplished in a spray application, a metered roller application, orany other suitable coating method. By way of example only, the curingprocess may be accomplished using a steam-filled-can drying system, athrough-air drying system, a radiation curing system, or any othersuitable method. By way of example only, the slitting process may beaccomplished using a slitting blade that may be comprised of a metal orceramic, a rotating slitting wheel, an air or water jet, or any othersuitable slitting method. By way of example only, the laminating processmay be accomplished by compressing the laminate layers between tworollers, by ultrasonic bonding, by chemical adhesion, or any othersuitable laminating method. Those of ordinary skill in the art willappreciate the variety of methods suitable for use in coating, curing,slitting, and laminating.

Having shown and described various embodiments, further adaptations ofthe methods and systems described herein may be accomplished byappropriate modifications by one of ordinary skill in the art withoutdeparting from the scope of this disclosure. Several of such potentialmodifications have been mentioned, and others will be apparent to thoseskilled in the art. For instance, the examples, embodiments, geometrics,materials, dimensions, ratios, steps, and the like discussed above areillustrative and are not required. Accordingly, the scope of the presentinvention should be considered in terms of whatever claims recite theinvention, and is understood not to be limited to the details ofstructure and operation shown and described in the description.

1. A method of continuously manufacturing a multilayerpressure-sensitive adhesive laminate comprising the steps of: a.producing a web having a first surface defined by an adhesive layer anda second surface defined by a release liner; b. slitting the weblongitudinally into a first section and a second section, each sectionhaving a first surface defined by an adhesive layer and a second surfacedefined by a release liner; c. positioning the first section and secondsection so the adhesive layer of the first section faces the adhesivelayer of the second section along the length of the first and secondsections; and d. laminating the first section and second sectiontogether such that the adhesive layers of the first and second sectionsare attached; wherein the resultant laminate has a first release linerdefining a first outer surface, a second release liner defining a secondouter surface, and an adhesive layer positioned between the first andsecond release liners.
 2. The method of claim 1 wherein the act ofpositioning the first and second sections further comprises: a. turningthe first section, wherein the act of turning causes the first sectionto change direction and position that the adhesive layer faces to oneopposite from a position prior to turning; b. turning the secondsection, wherein the act of turning causes the second section to changedirection and position that the adhesive layer faces to one oppositefrom a position prior to turning; and c. turning the second section asecond time, wherein the act of turning causes the second section tochange direction and position that the adhesive layer faces to oneopposite from a position prior to turning the second section a secondtime; wherein after turning, the direction of the second section alignswith the direction of the first section; and wherein after turning, theadhesive layer of the second section faces the adhesive layer of thefirst section.
 3. The method of claim 2 wherein, a. the act of turningthe first section further comprises directing the first section over a45-degree turning roller; b. the act of turning the second sectionfurther comprises directing the second section over a 90-degree turningroller; and c. the act of turning the second section a second timefurther comprises directing the second section over a 45-degree turningroller.
 4. The method of claim 1 wherein the act of positioning thefirst and second sections further comprises: a. turning the firstsection at least once, wherein the act of turning causes the firstsection to change direction and position that the adhesive layer facesto one opposite from a position prior to turning; and b. turning thesecond section at least once, wherein the act of turning causes thesecond section to change direction and position that the adhesive layerfaces to one opposite from a position prior to turning; wherein thefirst section and second section are turned an unequal number of timessuch that after turning the sections is complete, the second sectionaligns with the direction of the first section, and the adhesive layerof the second section faces the adhesive layer of the first section. 5.The method of claim 4 wherein, a. the act of turning the first sectionat least once further comprises directing the first section over one ormore 45-degree turning rollers; and b. the act of turning the secondsection at least once further comprises directing the second sectionover one or more 45-degree turning rollers.
 6. A method of continuouslymanufacturing a multilayer pressure-sensitive adhesive laminatecomprising the steps of: a. producing a web having a first surfacedefined by an adhesive layer and a second surface defined by a releaseliner; b. slitting the web longitudinally into a first section and asecond section, each section having a first surface defined by anadhesive layer and a second surface defined by a release liner; c.laminating a backing film to the adhesive layer of the first section; d.removing the release liner of the laminate of step (c) exposing theadhesive layer of the first section; e. positioning the laminate of step(d) and the second section so the exposed adhesive layer of the laminateof step (d) faces the adhesive layer of the second section; and f.laminating the second section to the laminate of step (d), wherein theadhesive layer of the laminate of step (d) is positioned adjacent to theadhesive layer of the second section; wherein the final laminate has afirst layer comprising the backing film, a second layer comprising theadhesive layers, and a third layer comprising the release liner.
 7. Themethod of claim 6 wherein the act of positioning the laminate of step(d) and the second section further comprises: a. turning the secondsection, wherein the act of turning causes the second section to changedirection and position that the adhesive layer faces to one oppositefrom a position prior to turning; and b. turning the laminate of step(d), wherein the act of turning causes the laminate of step (d) tochange direction and position that the adhesive layer faces to oneopposite from a position prior to turning; wherein after turning, thedirection of the laminate of step (d) aligns with the direction of thesecond section; and wherein after turning, the adhesive layer of thelaminate of step (d) faces the adhesive layer of the second section. 8.The method of claim 7 wherein, a. the act of turning the second sectionfurther comprises directing the second section over a 45-degree turningroller; and b. the act of turning the laminate of step (d) furthercomprises directing the laminate of step (d) over a 45-degree turningroller.
 9. The method of claim 6 wherein the act of positioning thelaminate of step (d) and the second section further comprises turningthe laminate of step (d) and the second section over one or more turningrollers wherein the laminate of step (d) and the second section areturned an equal number of times before lamination.
 10. The method ofclaim 9 wherein at least one of the one or more turning rollers is a45-degree turning roller.
 11. A method of continuously manufacturing amultilayer pressure-sensitive adhesive laminate comprising the steps of:a. producing a web having a first surface defined by an adhesive layerand a second surface defined by a release liner; b. slitting the weblongitudinally into a plurality of sections, each of the plurality ofsections having a first surface defined by an adhesive layer and asecond surface defined by a release liner; c. laminating a backing filmto the adhesive layer of a first section of the plurality of sections;d. removing the release liner of the laminate of step (c) exposing theadhesive layer associated with the first section; e. positioning thelaminate of step (d) and a next section of the plurality of sections sothe exposed adhesive layer of the laminate of step (d) faces theadhesive layer of the next section; f. laminating the next section tothe laminate of step (d), wherein the adhesive layer of the laminate ofstep (d) is positioned adjacent to the adhesive layer of the nextsection; g. removing the release liner of the laminate of step (f)exposing the adhesive layer associated with the next section; and h.repeating steps (e) through (g) to achieve a plurality of laminatedlayers; wherein step (g) is omitted with the final laminated section ofthe plurality of sections, such that the final laminate has a firstlayer comprising the backing film, a second layer comprising theadhesive layers, and a third layer comprising the release liner.
 12. Themethod of claim 11 wherein step (e) further comprises turning the nextsection at least twice, wherein each step of turning causes the nextsection to change direction and position that the adhesive layer facesto one opposite from a position prior to turning, wherein after thefinal turning, the direction of the next section aligns with thedirection of the laminate of step (d), and wherein after the finalturning, the adhesive layer of the next section faces the adhesive layerof the laminate of step (d).
 13. The method of claim 12 wherein the stepof turning the next section at least twice further comprises directingthe second section over a 45-degree turning roller.
 14. The method ofclaim 11 wherein the total number of laminated adhesive layers is atleast two.